Zinc sulfide coupling agents

ABSTRACT

An article of manufacture includes a zinc sulfide layer and a coupling agent adhered to the zinc sulfide layer by a disulfide bond. The coupling agent comprises a functional group extending from the zinc sulfide layer.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of and claims benefit of U.S. patentapplication Ser. No. 14/563,371, filed Dec. 8, 2014, the entire contentsof which are incorporated herein in their entirety.

BACKGROUND

The present disclosure relates to zinc sulfide, more specifically tozinc sulfide modified surfaces.

Zinc sulfide is a material used in a variety of optical elements. Forsome applications, the performance of zinc sulfide optical elements canbe improved by coating or treating the zinc sulfide with organicpolymers. However, due to the fundamental chemical differences betweenthe ionic salt-like structure of the zinc sulfide and the non-polarnature of the polymers, the organic polymers poorly adhere to the zincsulfide surfaces. These differences in the chemical nature of the twomaterials can result in poor wetting of the zinc sulfide, which can leadto poor adhesion.

In other systems, adhesion promoters or primers can be used to couplethe organic polymers to the inorganic surfaces. For example, in glasses,silanes can be used as such a promoter/primer.

SUMMARY

According to one embodiment, an article of manufacture includes a zincsulfide layer and a coupling agent adhered to the zinc sulfide layer bya disulfide bond, wherein the coupling agent includes a functional groupextending from the zinc sulfide layer.

In another embodiment, an article of manufacture includes a zinc sulfidelayer and a polymer adhered to a surface of the zinc sulfide layer,wherein a coupling agent forming a disulfide bond is disposed betweenthe zinc sulfide layer and the polymer.

Yet, in another embodiment, a method of making an article of manufactureincludes attaching a polymer to a zinc sulfide surface, wherein acoupling agent extends from the polymer and forms a disulfide bond withthe zinc sulfide surface.

Additional features and advantages are realized through the techniquesof the present invention. Other embodiments and aspects of the inventionare described in detail herein and are considered a part of the claimedinvention. For a better understanding of the invention with theadvantages and the features, refer to the description and to thedrawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is nowmade to the following brief description, taken in connection with theaccompanying drawings and detailed description, wherein like referencenumerals represent like parts:

FIG. 1 is a diagram of a polymer attached to a zinc sulfide surface witha coupling agent.

FIG. 2A is a graphical illustration that demonstrates the contact angleformed between an epoxy polymer adhered to an untreated zinc sulfidesurface.

FIG. 2B is a graphical illustration that demonstrates the contact angleformed between an epoxy polymer adhered to a zinc sulfide surface with acoupling agent.

DETAILED DESCRIPTION

Disclosed herein are coupling agents to promote polymer adhesion to zincsulfide. In one embodiment, an article of manufacture includes a zincsulfide layer and a coupling agent adhered to the zinc sulfide layer bya disulfide bond. The coupling agent comprises a functional groupextending from the zinc sulfide layer. In another embodiment, an articleof manufacture includes a zinc sulfide layer and a polymer adhered to asurface of the zinc sulfide layer. A coupling agent forms a disulfidebond and is disposed between the zinc sulfide layer and the organicpolymer. Yet, in another embodiment, a method of making an article ofmanufacture includes attaching an organic polymer to a zinc sulfidesurface. A coupling agent extends from the organic polymer and forms adisulfide bond with the zinc sulfide surface.

The articles of manufacture can be any optical element. Non-limitingexamples of the articles are lenses, optical windows, sensors,detectors, domes, and beam splitters.

The following definitions and abbreviations are to be used for theinterpretation of the claims and the specification. As used herein, theterms “comprises,” “comprising,” “includes,” “including,” “has,”“having,” “contains” or “containing,” or any other variation thereof,are intended to cover a non-exclusive inclusion. For example, acomposition, a mixture, process, method, article, or apparatus thatcomprises a list of elements is not necessarily limited to only thoseelements but can include other elements not expressly listed or inherentto such composition, mixture, process, method, article, or apparatus.

As used herein, the articles “a” and “an” preceding an element orcomponent are intended to be nonrestrictive regarding the number ofinstances (i.e. occurrences) of the element or component. Therefore, “a”or “an” should be read to include one or at least one, and the singularword form of the element or component also includes the plural unlessthe number is obviously meant to be singular.

As used herein, the terms “invention” or “present invention” arenon-limiting terms and not intended to refer to any single aspect of theparticular invention but encompass all possible aspects as described inthe specification and the claims.

As used herein, the term “about” modifying the quantity of aningredient, component, or reactant employed refers to variation in thenumerical quantity that can occur, for example, through typicalmeasuring and liquid handling procedures used for making concentrates orsolutions. Furthermore, variation can occur from inadvertent error inmeasuring procedures, differences in the manufacture, source, or purityof the ingredients employed to make the compositions or carry out themethods, and the like. In one aspect, the term “about” means within 10%of the reported numerical value. In another aspect, the term “about”means within 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the reported numericalvalue.

As used herein, the term “coupling agent” means a compound having asulfur atom that can form a disulfide bond with zinc sulfide and afunctional group that can form a contact product with or bond with apolymer.

Zinc sulfide is a durable material that is intrinsically transparent torelatively long electromagnetic wavelengths in the far-infrared (IR)range. Such properties contribute to its use in applications whichrequire IR transmission capability, such as in IR detectors and missiledomes. Zinc sulfide articles can be produced by chemical vapordeposition (CVD), hot pressing techniques, and hot-isostatic pressing(HIP) techniques. Methods of forming a zinc sulfide surface are known inthe art. The conditions, such as temperature and vacuum pressure, underwhich a zinc sulfide object is formed are also known in the art. Thetransmission, thermal stability, and strength can depend on thesubstrate upon which the zinc sulfide is deposited. Depending on thesubstrate used and conditions employed, a zinc sulfide surface can besuitable to withstand conditions encountered by missiles, projectiles,satellites, and related devices. The present disclosure is not limitedto any zinc sulfide deposition or forming method, article shape, orapplication.

Coupling agents disclosed herein react with zinc sulfide to provide asubstantially non-polar surface or a polymer-reactive surface. Themodified zinc sulfide surface can be used to provide robust adherentinteractions between polymers and zinc sulfide. Polymeric coatingsprovide improved mechanical properties, stability and protection fromhandling damage.

The coupling agents have a first sulfur atom containing functional groupthat reacts with the zinc sulfide surface to form a stable covalentbond, a disulfide bond. The coupling agents also include a secondfunctional group that reacts with the polymer. Accordingly, the couplingagent forms a chemical bond between the zinc sulfide surface and thepolymer.

The disulfide-forming coupling agents improve various properties of thezinc sulfide surface. For example, when the coupling agent is bonded tothe zinc sulfide surface, the adhesion strength between the polymer andthe zinc sulfide is greater than an untreated, like zinc sulfide surfacewithout the coupling agent (see Example 1 below). The coupling agentalso improves polymer wetting of the zinc sulfide surface (see Example 1below).

FIG. 1 is an exemplary diagram 100 of a polymer 140 attached to a zincsulfide surface 110 with a coupling agent 130. Although the zinc sulfidesurface 110 is shown as a flat surface in FIG. 1, the zinc sulfidesurface 110 can be any shape. In a non-limiting example, the zincsulfide surface 110 can be curved, such as concave or convex. Thecoupling agent 130 can be any sulfur-containing compound that has areactive sulfur group that can form a disulfide bond 120 with a sulfuratom on the zinc sulfide surface 110. The coupling agent 130 alsoincludes a functional group (R) that extends from the surface of thezinc sulfide layer 110 and can interact with the polymer 140 ofinterest. The functional group (R) can be any group that can chemicallybond, adhesively bond, or interact with the polymer. The functionalgroup (R) can form a contact product with the polymer.

The coupling agent can be a thiol, a thiolate, a thioglycolic acid, or athioglycolic acid salt. The coupling agent can include any additionalfunctional groups or substitutions, provided that it includes a reactivesulfur-containing group that can form a disulfide bond with the zincsulfide surface. The coupling agent can have a carbon chain, such as analkyl, alkenyl, or alkynyl chain extending between the disulfide bondand the functional group. The alkyl, alkenyl, or alkynyl chain can haveany number of carbons, depending on the desired polymer and application.In one aspect, the coupling agent has a carbon chain with between about2 and about 18 carbons. In another aspect, the coupling agent has acarbon chain with between about 12 and about 16 carbons. Yet in anotheraspect, the coupling agent has a carbon chain with between about 6 andabout 18 carbons. Still yet, in another aspect, the coupling agent has acarbon chain with about or in any range between about 2, 3, 4, 5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 17, and 18 carbons.

The functional group on the coupling agent can be any group, dependingon the polymer of interest. Non-limiting examples of the functionalgroup include an acrylate group, an acyl halide group, an amide group,an amine group, a carboxylate group, a carboxylate thiol group, an epoxygroup, an ester group, an ether group, a halogen, a hydroxamic acidgroup, a hydroxyl group, a nitrate group, a nitrile group, a phosphategroup, a phosphine group, a phosphonic acid group, a silane group, asulfate group, a sulfide group, a sulfite group, a thiolate group, analkyl group, an alkenyl group, an alkynyl group, an aryl group, an azidegroup, an acetal group, an aldehyde group, a diene group, a cycloalkylgroup, a cycloaryl group, a polycycloaryl group, a substituted cycloarylgroup, or any combination thereof.

The polymer interacting with or bonding with coupling agent is notintended to be limited and depends on the application. Non-limitingexamples of suitable polymers include an acrylic polymer, an acrylatepolymer, a styrene polymer, a urethane polymer, an epoxy polymer, apolyester polymer, a polyvinyl polymer, a phenoxy polymer, a nylonpolymer, a melamine polymer, a fluorinated polymer, a polyvinyl alcoholpolymer, a silicone polymer, or any combination thereof. The polymerscan be homopolymers or copolymers and can include any additionalsubstitutions or functional groups. The thickness of the polymer layeris not intended to be limited. The thickness depends on the targetapplication.

The optimal conditions for forming a disulfide bond with the zincsulfide surface will depend on the particular coupling agent used. Thesolvents, temperatures, and reactant concentration can be tailoredaccordingly. A basic pH and oxidizing conditions can be used.

The order in which the zinc sulfide surface, the coupling agent, and thepolymer are combined can vary. For example, the coupling agent can befirst reacted with the zinc surface to form a disulfide bond, and thenthe polymer can be reacted with the coupling agent. Alternatively, thecoupling agent and polymer can be combined and reacted to form acoupling agent-polymer conjugate, and the coupling agent-polymerconjugate can be reacted with the zinc sulfide surface. For example, thecoupling agent can be reacted with the polymer to form a zinc-sulfidereactive polymer before attaching the polymer to the zinc sulfidesurface.

Isothiouronium salts can be used to couple the polymer to the zincsulfide surface. Isothiouronium can have the general formula:RSC(NH₂)₂]⁺, wherein R=alkyl, aryl. The hydrogen (H) groups can besubstituted with alkyl or aryl groups. The isothiouronium also has afunctional group to interact or bind the polymer, as described below.

In one example, isothiouronium salts can have the following structure:

wherein n is an integer from about 2 to 18, X is a functional group thatcan interact with or bond to the polymer, and Y⁻ is an anion that canform a salt with the isothiouronium group.

Other suitable isothiouronium salts can have the following structure:

wherein R is an alkyl chain, alkenyl chain, alkynyl chain, or aryl chaincontaining any number of carbons and optionally substituted with anyfunctional groups; X is a functional group that can interact with orbond to the polymer; and Y⁻ is an anion that can form a salt with theisothiouronium group.

Other non-limiting examples of suitable isothiouronium salts includethose having the following structure:

wherein R₁, R₂, R₃, R₄, and R₅ are each independently a hydrogen, analkyl chain, an alkenyl chain, an alkynyl chain, or an aryl chaincontaining any number of carbons, for example from about 1 to about 18,and can be substituted with any functional groups; X is a functionalgroup that can interact with or bond to the polymer; and Y⁻ is an anionthat can form a salt with the isothiouronium group. Non-limitingexamples for each of R₂, R₃, R₄, and R₅ are methyl groups, ethyl groups,propyl groups, butyl groups, or any combination thereof.

Any method known in the art can be used to make isothiouronium salts.Scheme 1 below is an exemplary non-limiting method using an SN₂substitution reaction:

wherein n is any integer, for example between 2 and 18; X is afunctional group that can interact with or bond to a polymer ofinterest; and Y⁻ is a leaving group that can be replaced in an SN₂substitution reaction. As shown, thiourea (1) reacts with compound (2)with the formula: X(CH₂)_(n)Y. Y is substituted for the sulfur inthiourea to form the isothiouronium salt (3).

Non-limiting examples of X, as described above, include an acrylategroup, an acyl halide group, an amide group, an amine group, acarboxylate group, a carboxylate thiol group, an epoxy group, an estergroup, an ether group, a halogen, a hydroxamic acid group, a hydroxylgroup, a nitrate group, a nitrile group, a phosphate group, a phosphinegroup, a phosphonic acid group, a silane group, a sulfate group, asulfide group, a sulfite group, a thiolate group, an alkyl group, analkenyl group, an alkynyl group, an aryl group, an azide group, anacetal group, an aldehyde group, a diene group, a cycloalkyl group, acycloaryl group, a polycycloaryl group, a substituted cycloaryl group,or any combination thereof.

Non-limiting examples of the leaving group, Y, include a protonatedhydroxide group, an amino group, an alkoxide group, a fluoride, achloride, a bromide, an iodide, a methyl sulfate group, amethanesulfonate (mesylate) group, a trifluoromethanesulfonate(triflate) group, a 4-methanebenzenesulfonate (tosylate) group, adialkylether group, a nitrate group, a phosphate group, an ammoniumgroup, an inorganic ester group, a carboxylate group, a phenoxide group,or an amide group. A hydroxyl group can react with, for example,isocyante to form a urethane. A hydroxyl group can also react with anepoxy polymer.

As shown in Scheme 2 below, the isothiouronium salt (3) is thenhydrolyzed with any basic compound (4) to provide the reactive thiol (5)that can form the disulfide bond with zinc sulfide (see FIG. 1).

Any of the above described isothiouronium salts can be hydrolyzed andbonded to a zinc sulfide surface and a polymer of interest. The base orbasic compound can be any compound, reactant, or solution with a pHvalue sufficient to hydrolyze the isothiouronium salt. For example, thepH of the base or basic compound can be greater than 7. Non-limitingexamples of the base or basic compound include a carbonate compound, ahydroxide compound, a cyanide compound, a borate compound, a phosphatecompound, a pyrophosphate compound, a sulfite compound, a sulfidecompound, or any combination thereof. The base or basic compound can bea silicate of an alkali metal, including sodium, potassium, lithium,rubidium and cesium; a carbonate compound, a hydroxide compound, acyanide compound, a borate compound, or a sulfide of ammonia; analkoxide of an alkali metal; a quaternary ammonium hydroxide, or anycombination thereof.

One advantage of using an isothiouronium salt is that it provides aprotective group, the isothiouronium group, which allows forintroduction of a variety of functional groups (X) into the couplingagent that might otherwise prematurely intra-molecularly interact with areactive thiolate group. Thus, the protective group allows for formationof the disulfide bond when desired or appropriate.

The isothiouronium salts can be first reacted with the polymer to forman isothiouronium salt-polymer conjugate. The isothiouroniumsalt-polymer conjugate can then hydrolyzed with a base and then disposedonto the zinc sulfide surface to form a disulfide bond. However, theisothiouronium salt-polymer conjugate can be first disposed onto thezinc sulfide surface and then hydrolyzed with a base at high pH to formthe disulfide bond.

Alternatively, the isothiouronium salt can be first hydrolyzed anddisposed onto the zinc sulfide surface to form a disulfide bond. Then,the isothiouronium salt bonded to the zinc sulfide surface can behydrolyzed with a base and then reacted with the polymer.

The coupling agents can be prepared by any method or procedure known inthe art. In one non-limiting example, isothiouronium salts can beprepared by reacting thiourea and the corresponding compound having anappropriate leaving group, such as X(CH₂)_(n)Y, in an inert, polar,organic solvent (e.g., ethanol) at a temperature of from about 50° toabout 80° C. for about 4 to 6 hours. If a precipitate forms uponcooling, it can be filtered and recrystallized from ethanol. If noprecipitate forms upon cooling, then the ethanol is removed by rotaryevaporation and the residue is employed without further purification.

EXAMPLES

Equimolar amounts of thiourea and bromododecanol were reacted to form1-dodecanol-12-isothiouronium bromide. 1-dodecanol-12-isothiouroniumbromide was reacted with a 0.1 M sodium hydroxide to provide a reactivethiolate. An optical lens having a zinc sulfide surface was treated withthe reactive thiolate.

As shown in FIG. 2B, a “dot” of epoxy resin was disposed onto thetreated/coupled zinc sulfide surface. The contact angle, or angle formedbetween the zinc sulfide surface 230 and the epoxy resin “dot” 240 was29°.

For comparison, FIG. 2A shows a cured “dot” of epoxy resin disposed ontoan untreated (without the coupling agent) zinc sulfide surface. Thecontact angle between the untreated zinc sulfide surface 210 and theepoxy “dot” 220 was 49°. These results demonstrated improved wetting ofthe zinc sulfide surface on a treated lens.

The treated/coupled zinc sulfide surface also demonstrated improvedadhesion compared to the untreated surface. A wooden orange stick wasused to attempt to push the epoxy dots off the surfaces of the untreatedand treated zinc sulfide surfaces. The cured epoxy dot was easily pushedoff the surface of the untreated zinc sulfide surface (FIG. 2A). Yet thecured epoxy dot could not be removed from the surface of thetreated/coupled zinc sulfide (FIG. 2B).

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the present invention has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the invention in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention. Theembodiments were chosen and described in order to best explain theprinciples of the invention and the practical application, and to enableothers of ordinary skill in the art to understand the invention forvarious embodiments with various modifications as are suited to theparticular use contemplated.

While the preferred embodiments to the invention have been described, itwill be understood that those skilled in the art, both now and in thefuture, may make various improvements and enhancements which fall withinthe scope of the claims which follow. These claims should be construedto maintain the proper protection for the invention first described.

What is claimed is:
 1. A method of making an optical element, the methodcomprising: reacting a coupling agent with a zinc sulfide surface, at abasic pH, to form a covalent disulfide bond between the coupling agentand the zinc sulfide surface; and reacting an organic polymer with thecoupling agent.
 2. A method of making an optical element, the methodcomprising: treating an isothiouronium salt with a basic compound toform a coupling agent; reacting the coupling agent with a zinc sulfidesurface, at a basic pH, to form a covalent disulfide bond between thecoupling agent and the zinc sulfide surface; and reacting an organicpolymer with the coupling agent.
 3. The method of claim 2, furthercomprising reacting thiourea with a compound having the followingformula: X(CH₂)_(n)Y to form the isothiouronium salt; wherein X is anacrylate group, an acyl halide group, an amide group, an amine group, acarboxylate group, a carboxylate thiol group, an epoxy group, an estergroup, an ether group, a halogen, a hydroxamic acid group, a hydroxylgroup, a nitrate group, a nitrile group, a phosphate group, a phosphinegroup, a phosphonic acid group, a silane group, a sulfate group, asulfide group, a sulfite group, a thiolate group, an alkyl group, analkenyl group, an alkynyl group, an aryl group, an azide group, anacetal group, an aldehyde group, a diene group, a cycloalkyl group, acycloaryl group, a polycycloaryl group, a substituted cycloaryl group,or any combination thereof; and Y is a hydroxide group, an amino group,an alkoxide group, a fluoride, a chloride, a bromide, an iodide, amethyl sulfate group, a mesylate group, a triflate group, a tosylategroup, a dialkylether group, a nitrate group, a phosphate group, anammonium group, an inorganic ester group, a carboxylate group, aphenoxide group, or an amide group.
 4. The method of claim 1, whereinthe coupling agent has a functional group that forms a contact productwith the organic polymer.
 5. The method of claim 4, wherein thefunctional group is an acrylate group, an acyl halide group, an amidegroup, an amine group, a carboxylate group, a carboxylate thiol group,an epoxy group, an ester group, an ether group, a halogen, a hydroxamicacid group, a hydroxyl group, a nitrate group, a nitrile group, aphosphate group, a phosphine group, a phosphonic acid group, a silanegroup, a sulfate group, a sulfide group, a sulfite group, a thiolategroup, an alkyl group, an alkenyl group, an alkynyl group, an arylgroup, an azide group, an acetal group, an aldehyde group, a dienegroup, a cycloalkyl group, a cycloaryl group, a polycycloaryl group, asubstituted cycloaryl group, or any combination thereof.
 6. The methodof claim 4, wherein the coupling agent has an alkyl, alkenyl, or alkynylchain extending between the covalent disulfide bond and the functionalgroup.
 7. The method of claim 6, wherein the alkyl, alkenyl, or alkynylchain has between 12 and 16 carbons.
 8. The method of claim 1, whereinan adhesion strength between the organic polymer and the zinc sulfidesurface is greater than a like zinc sulfide surface without the couplingagent.
 9. The method of claim 1, wherein the optical element is a lens,an optical window, a sensor, or a detector.
 10. The method of claim 1,wherein the coupling agent comprises a thiol, a thiolate, a thioglycolicacid, or a thioglycolic acid salt.
 11. The method of claim 1, whereinthe organic polymer is an acrylic polymer, an acrylate polymer, astyrene polymer, a urethane polymer, an epoxy polymer, a polyesterpolymer, a polyvinyl polymer, a phenoxy polymer, a nylon polymer, amelamine polymer, a fluorinated polymer, a polyvinyl alcohol polymer, ora silicone polymer.
 12. An optical element comprising: a zinc sulfidelayer; and a coupling agent adhered to the zinc sulfide layer by acovalent disulfide bond; wherein the coupling agent comprises afunctional group extending from the zinc sulfide layer that forms acontact product with or bonds to an organic polymer.
 13. The opticalelement of claim 12, wherein the optical element is a lens, an opticalwindow, a sensor, a detector, a dome, or a beam splitter.
 14. Theoptical element of claim 12, wherein the functional group is an acrylategroup, an acyl halide group, an amide group, an amine group, acarboxylate group, a carboxylate thiol group, an epoxy group, an estergroup, an ether group, a halogen, a hydroxamic acid group, a hydroxylgroup, a nitrate group, a nitrile group, a phosphate group, a phosphinegroup, a phosphonic acid group, a silane group, a sulfate group, asulfide group, a sulfite group, a thiolate group, an alkyl group, analkenyl group, an alkynyl group, an aryl group, an azide group, anacetal group, an aldehyde group, a diene group, a cycloalkyl group, acycloaryl group, a polycycloaryl group, a substituted cycloaryl group,or any combination thereof.
 15. The optical element of claim 12, whereinthe coupling agent has an alkyl, alkenyl, or alkynyl chain extendingbetween the disulfide bond and the functional group.
 16. The opticalelement of claim 15, wherein the alkyl, alkenyl, or alkynyl chain hasbetween about 2 and about 18 carbons.
 17. The optical element of claim12, wherein an adhesion strength between the organic polymer and thezinc sulfide layer is greater than a like zinc sulfide layer without thecoupling agent.
 18. The optical element of claim 12, wherein thecoupling agent comprises a thiol, a thiolate, a thioglycolic acid, or athioglycolic acid salt.
 19. The optical element of claim 12, wherein thecoupling agent has an alkyl, alkenyl, or alkynyl chain extending betweenthe disulfide bond and the functional group, and the alkyl, alkenyl, oralkynyl chain has between 12 and 16 carbons.
 20. The optical element ofclaim 12, wherein the organic polymer is an acrylic polymer, an acrylatepolymer, a styrene polymer, a urethane polymer, an epoxy polymer, apolyester polymer, a polyvinyl polymer, a phenoxy polymer, a nylonpolymer, a melamine polymer, a fluorinated polymer, a polyvinyl alcoholpolymer, or a silicone polymer.